Note
Always be sure to check the tightening torque.
If the pressure lines are leaking after installation, they must be replaced.
Do not overtighten the pressure lines.
All pressure lines may only be reused 3 times. After the 3rd time, they must be replaced.
INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY
Using an E8 "TORX" socket wrench, install the No. 2 oil nozzle sub-assembly with the bolt.
INSTALL INJECTION PUMP DRIVE GEAR
| *a | Cutout |
| *b | Protrusion |
Align the cutout of the fuel supply pump assembly with the protrusion of the cylinder block and temporarily install the fuel supply pump with the 2 bolts.
Set the chain sub-assembly to the crankshaft.
| *a | 0.5 to 1.0 mm (0.0197 to 0.0394 in.) |
Install SST by rotating the crankshaft as shown in the illustration.
| SST |
|---|
| PZ4TB-04964-42 |
Tech Tips
The No. 1 piston position is 0.5 to 1.0 mm (0.0197 to 0.0394 in.) lower than the top of the cylinder block.
Install the injection pump drive gear with the chain sub-assembly.
Install the fuel supply pump assembly with the 2 bolts.
Install the central bolt to the injection pump drive gear
Temporarily install the fuel supply pump assembly support with the 4 bolts by hand in the order shown in the illustration.
Tighten the 4 bolts in the order shown in the illustration.
INSTALL TIMING CHAIN GUIDE
Using a T45 "TORX" socket wrench, install the timing chain guide with the 2 bolts.
INSTALL TIMING CHAIN TENSION ARM
Using a T45 "TORX" socket wrench, install the timing chain tension arm with the bolt.
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
Using an E8 "TORX" socket wrench, install the No. 1 chain tensioner assembly with the 2 bolts.
Remove the 3.0 mm hexagon wrench from the No. 1 chain tensioner assembly.
Remove SST.
| SST |
|---|
| PZ4TB-04964-42 |
INSTALL NO. 2 TIMING CHAIN TENSION ARM
Using a T45 "TORX" socket wrench, install the No. 2 timing chain tension arm with the bolt.
INSTALL NO. 2 CHAIN SUB-ASSEMBLY
Install the No. 2 chain sub-assembly to the injection pump drive gear.
INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY
Install the oil pump drive chain sub-assembly to the crankshaft.
INSTALL TIMING CHAIN COVER PLATE
Apply seal packing in a continuous line as shown in the illustration.
| Standard seal diameter |
|---|
| 1.5 to 2.0 mm (0.0590 to 0.0787 in.) |
Note
Remove any oil from the contact surface.
Install the timing chain cover plate within 3 minutes after applying seal packing.
Do not start the engine for at least 4 hours after installation.
Using an E8 "TORX" socket wrench, install the timing chain cover plate with the 11 bolts.
Apply a light coat of engine oil to a new O-ring, and install it to the sealing cap.
Install the sealing cap to the timing case housing.
INSTALL REAR ENGINE OIL SEAL
Using SST, tap in a new rear engine oil seal until its surface is flush with the rear oil seal retainer edge.
Note
Do not tap the rear engine oil seal at an angle.
INSTALL OIL PUMP WITH VACUUM PUMP ASSEMBLY
Install the oil pump drive chain sub-assembly to the oil pump drive shaft gear, and then install the oil pump with vacuum pump assembly.
Using an E10 "TORX" socket wrench, install the oil pump with vacuum pump assembly with the 4 bolts.
INSTALL OIL STRAINER SUB-ASSEMBLY
Install the oil strainer sub-assembly with the 2 bolts.
Tech Tips
Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.
INSTALL OIL PAN SUB-ASSEMBLY
Remove any old seal packing material.
Apply seal packing to the oil pan sub-assembly as shown in the illustration.
| Standard seal packing diameter |
|---|
| 2.0 to 2.5 mm (0.0787 to 0.0984 in.) |
Note
Remove any oil from the contact surface.
After applying seal packing, install the oil pan sub-assembly within 3 minutes and tighten the bolts.
Using an E10 "TORX" socket wrench, temporarily install the oil pan sub-assembly with the 24 bolts.
Tighten the 20 bolts.
Tighten the 4 bolts.
INSTALL FLYWHEEL WITH DAMPER ASSEMBLY
Install the crankshaft position sensor plate to the crankshaft.
Temporarily install the flywheel with damper assembly with 8 new bolts.
Using SST, fix the flywheel with damper assembly.
| SST |
|---|
| PZ4TB-04939-38 |
Using SST, tighten the 8 bolts.
| SST |
|---|
| PZ4TB-04910-18 |
Remove SST.
INSTALL CLUTCH DISC ASSEMBLY
Insert SST into the clutch disc, and then insert them into the flywheel.
Note
Insert the clutch disc with the disc facing in the correct direction.
INSTALL CLUTCH COVER ASSEMBLY
| *a | Matchmark |
Align the matchmark on the clutch cover with the one on the flywheel.
Install and tighten the 6 bolts uniformly in the order shown in the illustration, starting with the bolt located near the knock pin on the top.
Note
Be sure to uniformly tighten the bolts 180° at a time according to the order in the illustration.
Move SST up and down, right and left lightly after checking that the clutch disc assembly is in the center, and then tighten the bolts.
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
Using a dial indicator with a roller instrument, measure the diaphragm spring tip alignment.
| Maximum misalignment |
|---|
| 1.3 mm (0.0512 in.) |
If the misalignment is more than the maximum, using SST, adjust the diaphragm spring tip alignment.
INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
Using an 8 mm hexagon wrench, install SST (A) to the crankshaft.
| SST |
|---|
| PZ4TB-04961-27 |
Set a new timing gear case or timing chain case oil seal to the cylinder block.
Install SST (B) to SST (A).
| SST |
|---|
| PZ4TB-04961-27 |
Install and tighten SST (C) to install the timing gear case or timing chain case oil seal to the crankshaft.
| SST |
|---|
| PZ4TB-04961-27 |
Tech Tips
Tighten SST (C) until SST (B) contacts the cylinder block.
Remove SST (C), SST (B) and SST (A).
INSTALL CRANKSHAFT PULLEY
Using SST, hold the flywheel sub-assembly.
| SST |
|---|
| PZ4TB-04951-26 |
Install the crankshaft pulley to the crankshaft with 4 new bolts.
Tech Tips
The crankshaft pulley bolts are tightened in 2 progressive steps.
Step 1:
Using an E10 "TORX" socket wrench, tighten the 4 bolts.
Step 2:
Mark the RH side of the each crankshaft pulley bolt with paint.
Tighten the bolts 120°.
Check that the paint marks are now at a 120° angle to the RH side.
Remove SST.
Install the plug to the cylinder block.
SELECT CYLINDER HEAD GASKET
Check the piston protrusions for each cylinder.
Clean the cylinder block with solvent.
Set the piston of the cylinder to be measured to slightly before TDC.
| *a | Measuring Tip |
| *b | Measuring Point |
| *c | Protrusion |
Using SST, place a dial indicator on the cylinder block and set the measuring tip as shown in the illustration.
| SST |
|---|
| PZ4TB-04901-85 |
Set the dial indicator at 0 mm (0 in.).
Tech Tips
Make sure that the measuring tip is perpendicular to the cylinder head gasket surface and piston head when taking the measurements.
Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclockwise.
Measure each cylinder at 2 places for a total of 8 measurements.
For the piston protrusion value of each cylinder, use the average of the 2 measurements of each cylinder.
| Standard piston protrusion |
|---|
| 0.420 to 0.680 mm (0.0165 to 0.0267 in.) |
If the protrusion is not as specified, remove the piston sub-assembly and connecting rod sub-assembly and reinstall them.
| *a | Cylinder Head Gasket Hole |
|
Front |
Select a new cylinder head gasket.
| New Installed Cylinder Head Gasket Thickness | ||||||||
|---|---|---|---|---|---|---|---|---|
|
Tech Tips
Cylinder head gaskets have 1, 2, or 3 holes.
Select the largest piston protrusion value from the measurements and then select a new appropriate gasket according to the table below.
| Item | Specified Condition | ||
|---|---|---|---|
| Piston Protrusion | 0.42 mm (0.0165 in.) or less | 0.42 to 0.53 mm (0.0165 to 0.0208 in.) | 0.53 to 0.68 mm (0.0208 to 0.0267 in.) |
| Cylinder Head Gasket Holes | 1 Hole | 2 Holes | 3 Holes |
INSTALL CYLINDER HEAD GASKET
Place the cylinder head gasket in position on the cylinder block.
INSTALL CYLINDER HEAD SUB-ASSEMBLY
Note
Do not reuse the cylinder head bolts.
Make sure the ring pin shown in the illustration is not loose, deformed or otherwise damaged.
Place the cylinder head sub-assembly on the cylinder head gasket.
Note
Be careful of the installation direction.
Using an E10 "TORX" socket wrench, temporarily install the 5 bolts.
Apply a light coat of engine oil to under the heads of the new cylinder head bolts.
Note
Do not reuse the cylinder head bolts.
Temporarily install the new cylinder head bolts.
Step 1:
Using an E18 "TORX" socket wrench, uniformly tighten the 10 cylinder head bolts in several steps in the sequence shown in the illustration.
Mark the front of each cylinder head bolts head with paint.
Loosen the cylinder head bolts by 180° in the sequence shown in the illustration.
Step 2:
Tighten the 10 cylinder head bolts in several steps in the sequence shown in the illustration.
Retighten the cylinder head bolts by 120°.
Step 3:
Tighten the cylinder head bolts 120° further.
Check that the paint marks are now at a 240° angle to the RH.
Using an E10 "TORX" socket wrench, tighten the 5 bolts.
INSPECT VALVE LASH ADJUSTER ASSEMBLY
Note
Keep the valve lash adjuster free from dirt and foreign objects.
Use only clean engine oil.
Place the valve lash adjuster assembly into a container full of new engine oil.
Insert SST tip into the valve lash adjuster plunger and use the tip to press down on the check ball inside the plunger.
| *a | CORRECT | *b | INCORRECT |
| *c | Taper Port | *d | Plunger |
| *e | Lower Pressure Chamber | *f | Check Ball |
| *g | High Pressure Chamber | - | - |
Squeeze SST and the valve lash adjuster together to move the plunger up and down 5 to 6 times.
Check the movement of the plunger and bleed air.
| OK |
|---|
| Plunger moves up and down. |
Note
When bleeding high-pressure air from the compression chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.
After bleeding air, remove SST. Then quickly and firmly press the plunger repeatedly with your fingers.
| OK |
|---|
| Plunger can be pressed 3 times. |
If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster assembly with a new one.
INSTALL VALVE LASH ADJUSTER ASSEMBLY
Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.
Note
Install the valve lash adjuster assemblies to their original positions.
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
Install the 16 No. 1 valve rocker arm sub-assemblies.
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
Install 4 new gaskets.
Uniformly tighten the 14 bolts in several steps in the sequence shown in the illustration.
Using an E10 "TORX" socket wrench, install camshaft housing sub-assembly with the 14 bolts.
SET NO. 1 CYLINDER TO TDC/COMPRESSION
Remove the plug from the cylinder block.
Set SST (A) to the plug hole of the cylinder block.
| SST(A) |
|---|
| PZ4TB-04951-26 |
| *1 | Flywheel with Damper Assembly |
| *a | Groove |
Using SST (B), turn the crankshaft pulley clockwise until SST(A) fits into the groove of the flywheel with damper assembly.
| SST (B) |
|---|
| PZ4TB-04933-80 |
Using SST(A), hold the flywheel with damper assembly.
| SST (A) |
|---|
| PZ4TB-04951-26 |
Remove SST.
Install the plug to the cylinder block.
INSTALL CAMSHAFT AND NO. 2 CAMSHAFT
Apply clean engine oil to the cam lobe of each camshaft, journals of the camshaft housing sub-assembly and No. 1 valve rocker arm sub-assemblies.
Place the camshaft and No. 2 camshaft on the camshaft housing sub-assembly as shown in the illustration so that mark E and mark A face upward.
| *a | Mark E (Intake Side) |
| *b | Mark A (Exhaust Side) |
Note
Before and after setting the camshaft and No. 2 camshaft on the camshaft housing sub-assembly, check that the No. 1 valve rocker arm sub-assembly is firmly set to the valve lash adjuster assembly.
| *1 | No. 1 Valve Rocker Arm Sub-assembly |
| *2 | Valve Stem |
| *3 | Valve Lash Adjuster Assembly |
| *a | CORRECT |
| *b | INCORRECT |
| *a | Timing Mark |
Align the camshaft and No. 2 camshaft timing marks.
Set the 5 intake camshaft bearing caps and 5 exhaust camshaft bearing caps on the camshaft and No. 2 camshaft as shown in the illustration.
Using an E8 "TORX" socket wrench, partially tighten the 20 bolts.
Uniformly tighten the 20 bolts in several steps in the sequence shown in the illustration.
| *a | No clearance |
Using SST, hold the camshaft and No. 2 camshaft.
| SST |
|---|
| PZ4TB-04961-12 |
Note
Make sure there is no clearance between SST and the camshaft housing sub-assembly.
Using an E10 "TORX" socket wrench, temporarily install the camshaft timing sprocket with No. 2 chain sub-assembly to the camshaft with the 3 bolts.
Step 1:
Tighten the 3 bolts.
Step 2:
Loosen the 3 bolts 90°.
Using a T45 "TORX" socket wrench, install the No. 2 timing chain guide with the bolt.
Using a 24 mm socket wrench, install the No. 2 chain tensioner assembly.
Using an E10 "TORX" socket wrench, install the camshaft timing sprocket with the 3 bolts.
Remove SST from the camshaft.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Install 5 new gaskets to the cylinder head cover sub-assembly.
Install the cylinder head cover sub-assembly and tighten the 17 bolts.
Tech Tips
Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.
INSTALL OIL FILLER CAP SUB-ASSEMBLY
INSTALL OIL FILTER ASSEMBLY
Install a new gasket to the oil filter assembly.
Install the oil filter assembly with the 6 bolts.
INSTALL OIL FILTER SUB-ASSEMBLY
Clean the inside of the oil filter cover, its threads and its O-ring.
| *1 | O-Ring |
| *a | CORRECT |
| *b | INCORRECT |
Apply a small amount of engine oil to a new O-ring and install it to the oil filter cover.
Note
Be sure to install the O-ring in the proper location, otherwise oil may leak.
Do not twist the O-ring.
Apply a light coat of engine oil to a new O-ring.
| *1 | O-Ring |
| *a | Oil Filter Assembly Hole |
|
Protrusion |
Install the O-ring to the oil filter sub-assembly.
Set a new oil filter sub-assembly in the oil filter assembly.
Note
Insert the protrusion of the oil filter sub-assembly into the oil filter assembly hole.
Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cover.
| *1 | Oil Filter Assembly |
| *2 | O-Ring |
| *3 | Oil Filter Cover |
| *a | No Gap |
Using a 27 mm socket wrench, tighten the oil filter cover.
Note
After tightening the oil filter cover, make sure that there is no gap and that the O-ring is not protruding.
INSTALL WATER OUTLET
Install a new gasket to the water outlet.
Using an E10 "TORX" socket wrench, install the water outlet with the 3 bolts.
INSTALL WATER INLET HOUSING
Apply seal packing in a continuous line as shown in the illustration.
| Standard seal diameter |
|---|
| 2.0 to 2.5 mm (0.0787 to 0.0984 in.) |
Note
Remove any oil from the contact surface.
Install the water inlet housing within 3 minutes after applying seal packing.
Do not start the engine for at least 4 hours after installation.
Using an E11 "TORX" socket wrench, install the water inlet housing with the 5 bolts.
INSTALL THERMOSTAT
Align the jiggle valve with the top of the water inlet to install the jiggle valve.
INSTALL WATER INLET
Temporarily install the water inlet together with the thermostat with the 4 bolts by hand.
Using several steps, uniformly tighten the 4 bolts.
Tech Tips
Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.
INSTALL WATER BY-PASS PIPE
Using a 5 mm hexagon socket wrench, install the water by-pass pipe to the water inlet housing with the bolt.
Tech Tips
Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.
INSTALL ENGINE WATER PUMP ASSEMBLY
Apply seal packing in a continuous line as shown in the illustration.
| Standard seal diameter |
|---|
| 2.0 to 2.5 mm (0.0787 to 0.0984 in.) |
Note
Remove any oil from the contact surface.
Install the engine water pump assembly within 3 minutes after applying seal packing.
Do not start the engine for at least 4 hours after installation.
Install the engine water pump assembly with the 5 bolts.
INSTALL INJECTOR ASSEMBLY
Note
Before installing the injector assembly, check for carbon, foreign matter, etc. on the seal surfaces of the cylinder head sub-assembly and injector assembly. If there is foreign matter, remove it before installing the injector assembly.
Make sure to replace the copper sealing ring on the injector assembly.
| *1 | Copper Sealing Ring |
| *a | Point Above the Copper Sealing Ring |
| *b | Injector Assembly Slot End |
Before installing the injector assemblies to the injector assembly slots, apply a light coat of highly heat-resistant grease from above the top of the copper sealing ring to the injector assembly slot end.
Check the installation position of the high pressure connection.
Make sure to read the adjustment values each time new injector assemblies are installed.
Tech Tips
Perform "Inspection After Repairs" after replacing the fuel injector assembly Click here.
Install the 4 injector assemblies to the cylinder head cover sub-assembly.
Using an E10 "TORX" socket wrench, install the 4 clamping claws to the 4 injector assemblies with the 4 centering rings and 4 bolts.
Note
Retighten the clamping claw (cylinder head cover mounting).
Make sure the screw centering ring is correctly positioned in order to align the clamping claw.
Connect the 4 injector assembly connectors.
INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY
Install 4 new sealing rings and connect the nozzle leakage pipe assembly.
| *1 | Sealing Ring |
| *2 | Leakage Line |
| *3 | Rubber Grommet |
| *a | Downward |
Connect the nozzle leakage pipe assembly to the rubber grommet.
Install 4 new sealing rings to the nozzle leakage pipe assembly.
Attach the connection of the nozzle leakage pipe assembly downwards.
Connect the connector and attach the 2 clamps to connect the wire harness.
INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
Install a new gasket.
Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.
Connect the engine oil pressure switch connector.
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
Using a 17 mm (12P) deep socket wrench, install the engine coolant temperature sensor.
Connect the engine coolant temperature sensor connector.
INSTALL CRANKSHAFT POSITION SENSOR
Connect the crankshaft position sensor connector.
Using a T25 "TORX" socket wrench, install the crankshaft position sensor with the bolt.
INSTALL CAMSHAFT POSITION SENSOR
Apply a light coat of engine oil to the O-ring of the camshaft position sensor.
Note
When reusing the camshaft position sensor, inspect the O-ring.
Make sure that the O-ring is not cracked or jammed when installing the camshaft position sensor.
Using an E6 "TORX" socket wrench, install the camshaft position sensor with the bolt.
Connect the camshaft position sensor connector.